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7/25/2019 MFGT290 Plastics Composites Ceramics
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efinition of Plastics
ll Materials
GasesSi(ple
3i4i"sSoli"s
Metals Polymers
(polymeric molecules)Cera(ics
Ther(osets
Heat Setting
Ther(oplastics
Heat Forming
%lasto(ers
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Intro"ction) Pol*(eric (aterials can 5e either
6 Ther(oplastics, ther(osets, an" elasto(ers7
6 %ach section is presente" in appropriate &rops) Ther(oplastics' Heat For(in& (aterials 8Can reheat for( a&ain
6 Car5on 5on"s are Satrate" an" are sin&le 5on"s7
6 Co(e in a .ariet* of for(s
) Pellets, po/"er 81'100 (icrons:, fla;e, chip, c5e, "ice,
) Shippe" in pac;a&es of choice6
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Co((ercial Ther(oplastics) Olefins
6 Unsatrate", aliphatic h*"rocar5ons (a"e fro( eth*lene &as
6 %th*lene is pro"ce" 5* crac;in& hi&her h*"rocar5ons of natral &as orpetrole(
) 3P% co((erciali+e" in 199 in hi&h pressre process
)
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MaBor Plastic Materials199!
) 3P% D7! M (etric tons
) HP% #7 M (etric tons
) PC #71 M (etric tons
) PP !7! M (etric tons
) PS 27@ M (etric tons
) PU 17@ M (etric tons
) P%T 17D M (etric tons) Phenolic 17# M (etric tons
Total 2>7D M (etric tons8>2E of (ar;et:
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-ec*clin& of Plastics
) State an" Fe"eral 3e&islation
) P%T 5ottle rec*clin&) Co"es for plastics
6 1 P%T
6 2 HP%
6 in*lPC
6 ! 3P%
6 # PP
6 D PS6 @ Other
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) (orphos' Moleclar strctre is incapa5le of for(in& re&lar or"er8cr*stalli+in&: /ith (olecles or portions of (olecles re&larl* stac;e" in
cr*stal'li;e fashion7) ' (orphos 8/ith'ot shape:
) Usall* transparent 8Clear 5a&s:
) 3ess shrin;a&e /ith a(orphos (aterials7
States of Ther(oplastic Pol*(ers
(orphos Pol*(ers
)
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) Cr*stalline' Moleclar strctre for(s re&lar or"er 8cr*stals: /ith (olecles or portions of(olecles re&larl* stac;e" in cr*stal'li;e fashion7
) Most cr*stalline pol*(ers are se(i'cr*stalline 5ecase .er* fe/ plastics are 100Ecr*stalline7 ll ha.e 5oth re&ions that are cr*stalline an" so(e that are a(orphos
) Usall* Opa4e an" not transparent
) More (ol"in& shrin;a&e /ith6 cr*stalline (aterials7
States of Ther(oplastic Pol*(ers
Cr*stalline Materials
)3P% HP% PP
)P%T P
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Fnctional Grops
) Certain che(ical characteristics associate" /ith .arios &rops of
ato(s, calle" fnctional &rops7) Particlar &rops of ato(s occr in a lar&e (olecle, thecharacteristic che(istr* is anticipate"76 %=a(ple, PP has Fnctional &rops can 5e attache" to 5asic &rops of car5on
ato(s 5* replacin& on H ato(7
6ote$ PP is Mostl* Isotactic' CHon one si"e of pol*(er chain 8isolate":7Co((ercial PP is 90E to 9#E Isotactic an" not tactic 8ran"o(: or s*n"iotactic
C C
H CH
H H
n
C C
H CH
H H
n
C C
H CH
H H
n
C C
H CH
H H
n
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Fnctional Grops
) arios (olecles of car5on, h*"ro&en an" o=*&en illstratin& the
"ifferences properties /ith "ifferent ato(ic arran&e(ents) isoprop*l alcohol' r55in& alcohol) (eth*leth*l ether' anesthetic
) acetone' co((on sol.ent
) (eth*l acetate' s/eet che(ical perf(e
) propional"eh*"e' sharp s(ellin& che(ical) propanoic aci" relate" to .ine&ar
) ro(atic &rop' P
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Pol*(ers Units
) Jst as 2 car5ons ato(s are 5on"e" toðer in ethane, three, for, or
(ore car5ons can 5e 5on"e" in chain'li;e arran&e(ent, so(eti(esthosan"s of ato(s lon&7
) 3on& chains of ato(s are pol*'(ers 8(an*'(ers or nits:
) Fi&re
6 Pol*eth*lene PP PS PC
6ote$ PP is Mostl* Isotactic' CHon one si"e of pol*(er chain 8isolate":7
Co((ercial PP is 90E to 9#E Isotactic an" not tactic 8ran"o(: or s*n"iotactic
C C
H H
H H
n
C C
H CH
H H
n
C C
H Cl
H H
n
C C
H
H H
n
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Co(ple= Pol*(ers) Pol*(er chains /ith ato(s other than car5on
6 Usall* pol*(er chains /ith C an" , O, S, F, an" Cl
) PC has Cl *lon has O an" Pol*rethane has O an"
) P%T has O an" 5en+ene rin& PC has O an" 5en+ene rin&
)
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For(ation of Pol*(ers
) ""ition 8or Chain'Gro/th: Pol*(eri+ation
6 Most Co((o"it* 8cheap: plastics
6 Instantaneosl*, the pol*(er chain for(s /ith no 5*'pro"cts
6 Chain'reaction (echanis( that procee"s 5* se.eral se4ential steps
as sho/n in Fi&re 27207 Pol*(eri+ation 5e&ins at one location on
the (ono(er 5* an initiator
) Con"ensation 8or Step'/ise: Pol*(eri+ation6 Most %n&ineerin& plastics 8pellets of *lon, PC, P%T, Pol*rethane:an"
the(osets 8li4i"s of epo=*, pol*ester, pol*rethane:
6 Step'&ro/th pol*(eri+ation procee"s 5* se.eral steps /hich reslt in 5*'
pro"cts7
6 Mono(ers co(5ine to for( 5loc;s 2 nits lon&
6 2 nit 5loc;s for( !, /hich intern for( > an" son on ntil the process is
ter(inate"7
6 -eslts in 5*'pro"cts 8CO2, H2O, cetic aci", HCl etc7:
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*lon 8or pol*a(i"e: an" PC) The repeatin& 'COH' 8a(i"e: lin;
) Pol*(eri+e" /ith con"ensation reaction6*lon D' Pol*caprolacta($ NH8CH2:#CO=
6*lon D,D' Pol*he=a(eth*lenea"ipa(i"e$
) NH8CH2:DHCO 8CH2:!CO=
6*lon 12' Pol*812'a(ino"o"ecanoic aci":' NH8CH2:11CO=
) Pol*car5onates are linear, a(orphos pol*esters 5ecase the*
contain esters of car5onic aci" an" an aro(atic 5isphenol 8CDH#OH:
) Pol*(eri+e" /ith con"ensation reaction
O C
CH2
CH2C
O
O
n
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Ho(opol*(ers) Plastics In.ol.in& Three S5stittions 8se Ta5le 72:
C C
A
Q R
n
C C
F F
F F
n
e7&7 PTF%pol*tetrafloroeth*lene
8Teflon:
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Copol*(ers an" Ter Pol*(ers) Plastics In.ol.in& T/o (ers in chain or (ers 8
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Ther(osets
) Ther(osets are pol*(ers that n"er&o a che(ical reaction
"rin& the pol*(eri+ation7
) Ther(osettin& reaction is not re.ersi5le n"er heat7
) %po=*
6 Stan"ar" epo=* is 5ase" on 5isphenol an" epichloroh*"rin7
6 Properties incl"e &oo" a"hesion to (an* s5strates, lo/shrin;a&e, hi&h electrical resisti.it*, &oo" corrosion resistance, an"
ther(al7
6 Processin& is achie.e" /ithot &eneration of .olatiles7
P l t " P l th
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Pol*ester an" Pol*rethane) Pol*ester
6 Ther(oset reaction 5et/een a "ifnctional aci" 8or anh*"ri"e: an" a "ifnctional alcohol 8&l*col:
6 Heat or ra"iation can tri&&er the cross lin;in& reaction
6 ccelerators 8or pro(oters: spee" p the reaction7
6 Con"ensation -eaction reslts in CO2an" H2O76 Mono(er re4ire" to pol*(eri+e, e7&7, St*rene at 0E to #0E in co((ercial pol*ester s*ste(s
) Polrethane6 -eaction 5et/een isoc*anate an" alcohol 8pol*ol:7 Con"ensation -eaction reslts in CO 2an"
H2O7
6 Crosslin;in& occrs 5et/een isoc*anate &rops 8'CO: an" the pol*ol?s h*"ro=*l en"'&rops 8'OH:
6 Ther(oplastic PU 8TPU: ha.e so(e crosslin;in&, 5t prel* 5* ph*sical (eans7 These 5on"scan 5e 5ro;en re.ersi5l* 5* raisin& the (aterial?s te(peratre, as in (ol"in& or e=trsion7
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Ther(oplastic %lasto(ers, atral -55er
) Ther(oplastic %lasto(ers reslt fro( copol*(eri+ation of t/o or
(ore (ono(ers76 One (ono(er is se" to pro.i"e the har", cr*stalline featres, /hereas the other(ono(er pro"ces the soft, a(orphos featres7
6 Co(5ine" these for( a ther(oplastic (aterial that e=hi5its properties si(ilar tothe har", .lcani+e" elasto(ers7
) Ther(oplastic Urethanes 8TPU: /ere the first Ther(oplastic%lasto(er 8TP%: se" for seals &as;ets, etc7
) Other TP%s6 Copol*ester for h*"ralic hoses, coplin&s, an" ca5le inslation7
6 St*rene copol*(ers are less e=pensi.e than TPU /ith lo/er stren&th
6 St*rene'5ta"iene 8S
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Plastics estions17 5on" 5et/een 2 car5on ato(s is a KKKKKKK 5on"7
27 CH &rops is calle" a KKKKKKKKKK &rop7
7 "ash 5et/een ato(s in"icates a KKKKKK 5on"7
!7 The s(all repeatin& nits that (a;e p a plastic (olecle are calle" KKKKKKKKKKK
#7 Ahat "oes pol* (ean KKKKKKKKKKK
D7 t*pes of inter(oleclar forces fon" in plastics are KKKKKKKKKKK , KKKKKKKKKKKK, an"KKKKKKKKKKKK7
@7 Ahat t*pe of 5on"in& (a;es *lon D stron&er than n*lon 12 KKKKKKKKKKKKK
>7 Cr*stalline plastics are (ore ri&i" an" not as transparent as KKKKKKKKK plastics7
97 KKKKKKK (aterial (a* 5e softene" repeate"l* /hen heate" an" har"ene" /hen coole"7
107 The ter( se" to "escri5e t*in& toðer a"Bacent pol*(er chains is KKKKKKK
117 If the "ifferent (ers (a;e p the co(position of a pol*(er , it is calle" a KKKKKK7
127 H*"ro&en (olecle /hich contains so(e "o5le 5on"s is calle" KKKKKKKK7
17 Is PC a copol*(er KKKKKKKKK %=plain' KKKKKKKKKKKKKKKKKKKKKKKKKKKKK7
1!7 Ahat is the &eneral strctre of an alternatin& copol*(er KKKKKKKKKKKKKKKKKK71#7 If a car5on chain has a (eth*l si"e &rop, is it 5ranche" KKKKKKKKK %=plain'
KKKKKKKKKKKKKKKKKKKKKKKKKKKKK7
1D7 If a (aterial is transparent, is it cr*stalline KKKKKKKKKKKK
1@7 Ahat effect "o "ipoles an" h*"ro&en 5on"s ha.e on (eltin& point of pol*(ers KKKKKKKKKKK
1>7 Is resi"al stress s*non*(os /ith orientation KKKKKKKKKKKKKKKKKKKK
197 Ho/ "oes the tensile stren&th an" (eltin& point chan&e /ith increasin& cr*stalli+ation KKKKKK
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Processin& of Pol*(ers) Ther(oplastics
6inBection (ol"in&, e=trsion, 5lo/ (ol"in&, ther(ofor(in&,rotational (ol"in&, co(pression (ol"in&
6 Usall* ses hi&h pressre processes an" i(parts hi&h resi"al
stresses on the (aterial /hich an case /arpin& in part7
) Ther(osets6 co(pression (ol"in&, reaction inBection (ol"in&, resin transfer
(ol"in&, castin&, han" la*p, etc7
) %lasto(ers
6 co(pression (ol"in&, e=trsion, inBection (ol"in&, castin&7
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InBection Mol"in& Process an" C*cle Ti(e
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%=tr"er %4ip(ent) %=it +one' "ie
6 "ie i(parts shape on the (aterial, e7&7, ro", t5e, sheet, channel
6 e=it (aterial is calle" extrudate6 e=tr"ate s/ells at en" of "ie "e to nor(al forces fro( the pol*(er flo/, calle" die swell
) Cooling zone
6 /ater 5ath or air coole" to lo/er the te(peratre 5elo/ T&
) =iliar* e4ip(ent6 pller
6 rollers for proper thic;ness
6 Ain"'p or ct off
ie S/ell
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Co(pression Mol"in& Process)Materials
)Ther(osets$ Pol*ester, in*l ester, or %po=* resins /ith &lass fi5er)Sheet Mol"in& Co(pon" 8SMC:,
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2D
-esin Transfer Mol"in& Process-ef$ MSU Ttorial' http$islnotes7cps7(s7e"trpli4i"rt(
)Materials)Ther(osets$ Pol*ester, in*l ester, or %po=* resins /ith &lass fi5er
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Pol*rethane Processin&
) Pol*rethane can 5e processe" 5*
6 Castin&, paintin&, foa(in&
6 -eaction InBection Mol"in& 8-IM:
h i l
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Ther(oset -eactin& Pol*(ers) Process Ain"o/
6 Te(peratre an" pressre (st 5e set to pro"ce che(ical reaction
/ithot e=cess flash 8too lo/ a .iscosit*:, short shot 8too hi&h a
.iscosit*:, "e&ra"ation 8too (ch heat:
C i l"i
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Co(pression Mol"in&) Co(pression (ol"in& /as specificall* "e.elope" for replace(ent of (etal
co(ponents /ith co(posite parts7 The (ol"in& process can 5e carrie" ot /ith
either ther(osets or ther(oplastics7 Ho/e.er, (ost applications to"a* sether(oset pol*(ers7 In fact,co(pression (ol"in& is the (ost co((on (etho"
of processin& ther(osets7
- i T f M l"i
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-esin Transfer Mol"in&
) In the -TM process, "r* 8i7e7,ni(pre&nate" :
reinforce(ent is pre'shape" an" oriente" into s;eleton ofthe actal part ;no/n as the prefor( /hich is inserte" into
a (atche" "ie (ol"7
)The heate" (ol" is close" an" the li4i" resin is inBecte"
) The part is cre" in (ol"7
) The (ol" is opene" an" part is re(o.e" fro( (ol"7
I B i M l"i Gl - i f " C i
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InBection Mol"in& Glass -einforce" Co(posites
) Plastic pellets /ith &lass fi5ers are (elte" in scre/,
inBecte" into a col" (ol", an" then eBecte"7
Glass fille" resin pellets
Ch 1! C i
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Chap 1!$ Co(posites) Co(posite Materials
) Co(posite Constrction) Co(posite pplications
) Processin& of Co(posites
) -e.ie/ estions
P l C i
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Pol*(ers Co(posites
) O5Becti.es6 efine the co(ponents an" "ifference t*pes of co(posites7
6 %=plain the "ifferent t*pes of co(posite constrction an" the reasons 5ehin"
the(7
6 escri5e the .arios (anfactrin& (etho"s se" to pro"ce co(posites76 3ist the "ifferent reinforcin& (aterials se" in co(posites7
6 3ist the .arios (atri= (aterials se" in co(posites7
) %=cellent Ae5 sites
6 Michi&an State http://islnotes.cps.msu.edu/trp/
6 U of ela/are http://www.ccm.udel.edu/publications/CU/99/
6 Cornell Uni.ersit* http://www.engr.siu.edu/staff/abrate/!"#$%&/lin's.htm
C it
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Co(posites) Co(posite "efinition
6 co(posite is a (aterial co(prise" of t/o or (ore ph*sicall* "istinct
(aterials /ith at least one (aterial pro.i"in& reinforcin& properties onstren&th an" (o"ls7
) atral Co(posites6
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Co(posite Classifications
) -einforce(ent T*pe
6 iscontinos 8fi5ers are choppe" an" "isperse" in (atri= resin:) Short fi5ers$ fi5er len&ths (( or less 8(ost inBection (ol"e" (aterials:
) 3on& fi5ers$ fi5er len&ths &reater than D ((7 8So(e inBection (ol"e" (aterials /ith D(( fi5ers,Sheet Mol"in& Co(pon" 8SMC: /ith 1 fi5ers, FP irecte" Fi5er Prefor(s for -TM an" S-IM:
) Particlates$ fi5ers is for(s as spheres, plates, ellipsoi"s 8so(e inBection (ol"e" (aterialsreinforce" /ith (ineral fi5ers:
6 Continos 8fi5ers are thro&hot strctre /ith no 5rea; points:
) Glass ro.in&$ &lass 5n"les are /on" p in a pac;et si(ilar to *arn7
) -o.in& is /o.en into se.eral /ea.es sin& a loo( (achine li;e in apparel7
6 Mat pro"cts$ ran"o( s/irl &lass pattern7
6 Ao.en pro"ct$ ro.in& is /o.en into (achine "irection 8/arp: an" cross "irection 8/eft:
6 Uni pro"ct$ ro.in& is /o.en in one "irection /ith a cross threa" &i.en to hol" (attoðer7
Gl Fi5 li ti
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Glass Fi5er pplications) iscontinos 8Choppe": Fi5er
) Short fi5er 83 ((: reinforce(ent for ther(oplastic (aterials that are
inBection (ol"e" 8PP an" *lon:) 3on& Fi5er 83D((: reinforce(ent for ther(oplastic (aterials that are
inBection (ol"e" 8*lon:
) Choppe" Fi5er 8312 (( to 2# ((: reinforce(ent for ther(oset 8SMC
an"
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@
Car5onGraphite Fi5ers
) ee" for reinforce(ent fi5ers /ith stren&th an" (o"liihi&her than those of &lass fi5ers has le" to "e.elop(ent ofcar5on
) Tho(as %"ison se" car5on fi5ers as a fila(ent forelectric li&ht 5l5
) Hi&h (o"ls car5on fi5ers first se" in the 19#0s) Car5on an" &raphite are 5ase" on la*ere" strctres of
he=a&onal rin&s of car5on
) Graphite fi5ers are car5on fi5ers that
6 Ha.e 5een heat treate" to a5o.e 000F that cases "i(ensionalor"erin& of the ato(s an"
6 Ha.e car5on contents G-%T%- than 99E
6 Ha.e tensile (o"ls of !! Gpa 8#0Mpsi:
Car5onGraphite Fi5ers
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Car5onGraphite Fi5ers
) ee" for reinforce(ent fi5ers /ith stren&th an" (o"liihi&her than those of &lass fi5ers has le" to "e.elop(ent ofcar5on
) Tho(as %"ison se" car5on fi5ers as a fila(ent for electricli&ht 5l5
) Hi&h (o"ls car5on fi5ers first se" in the 19#0s) Car5on an" &raphite are 5ase" on la*ere" strctres of
he=a&onal rin&s of car5on
) Graphite fi5ers are car5on fi5ers that
6 Ha.e 5een heat treate" to a5o.e 000F that cases "i(ensionalor"erin& of the ato(s an"
6 Ha.e car5on contents G-%T%- than 99E
6 Ha.e tensile (o"ls of !! GPa 8#0Mpsi:
Car5onGraphite Fi5ers
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Car5onGraphite Fi5ers
) Manfactrin& Process
6 Crrent preferre" (etho"s of pro"cin& car5on fi5ers are fro(
pol*acr*lonitrile 8P:, ra*on 8re&enerate" celllose:, an" pitch7
) P
6 Ha.e &oo" properties /ith a lo/ cost for the stan"ar" (o"ls
car5on6 Hi&h (o"ls car5on is hi&her in cost 5ecase hi&h te(peratres
re4ire"
) PITCH
6 3o/er in cost than P fi5ers 5t can not reach properties of P
6 So(e Pitch 5ase" fi5ers ha.e ltra hi&h (o"ls 8@2# GPa .erss
#0GPa: 5t lo/ stren&th an" hi&h cost 8Ta5le '2:
Car5onGraphite Fi5ers
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!0
Car5onGraphite Fi5ers
) P Manfactrin& Process Fi&res ' an" '!
6 Pol*acr*lonitrile 8P: is co((erciall* a.aila5le te=tile fi5er an" is a rea"*
(a"e startin& (aterial for P'5ase" car5on fi5ers6 Sta5ili+e" 5* ther(osettin& 8crosslin;in&: so that the pol*(ers "o not (elt in
s5se4ent processin& steps7 P fi5ers are stretche" as /ell
6 Car5oni+e$ Fi5ers are p*rol*+e" ntil transfor(e" into all'car5on
) Heate" fi5ers 1>00F *iel"s P fi5ers at 9!E car5on an" DE nitro&en
) Heate" to 200F to re(o.e nitro&en *iel"s car5on at 997@E Car5on
6 Graphiti+e$ Carrie" ot at te(peratres &reater than 200 F to
) I(pro.e tensile (o"ls 5* i(pro.in& cr*stalline strctre an" three "i(ensional
natre of the strctre7
6Fi5ers are srface treate") Si+in& a&ent is applie"
) Finish is applie"
) Coplin& a&ent is applie"
6 Fi5ers are /on" p for ship(ent
Car5onGraphite Fi5ers
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Car5onGraphite Fi5ers
) PITCH Manfactrin& Process) Pitch (st 5e con.erte" into a sita5le fi5er fro( petrole( tar
) Pitch is con.erte" to a fi5er 5* &oin& thro&h a (eso'phase /here the pol*(erchains are so(e/hat oriente" tho&h is a li4i" state 8li4i" cr*stal phase:
) Orientation is responsi5le for the ease of consoli"ation of pitch into car5on
6 Sta5ili+e" 5* ther(osettin& 8crosslin;in&: so that the pol*(ers "o not (elt ins5se4ent processin& steps
6 Car5oni+e$ Fi5ers are p*rol*+e" ntil transfor(e" into all'car5on) Heate" fi5ers 1>00F
) Heate" to 200F
6 Graphiti+e$ Carrie" ot at te(peratres &reater than 200 F to
) I(pro.e tensile (o"ls 5* i(pro.in& cr*stalline strctre an" three "i(ensional
natre of the strctre76 Fi5ers are srface treate"
) Si+in& a&ent is applie"
) Finish is applie"
) Coplin& a&ent is applie"
6 Fi5ers are /on" p for ship(ent
Car5on Fi5er Mechanical Properties
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!2
Car5on Fi5er Mechanical Properties
) Ta5le '2 8fro( MFGT 10!:
Carbon Fiber Mechanical PropertiesPAN Based PITCH Based Rayon Based
Tensile Modulus (Mpsi) 33 !" #3 !! !$%
Tensile &tren'th (Msi) $* $3! $# $#! $+!
,lon'ation (-) +$ $" $% $ #!
.ensity ('/cc) +$* +$% +$% #$ +$"
Carbon Assay (-) %# + %0 %% %%
Co(posites Ha.e a Fi5er Prefor(
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!
Co(posites Ha.e a Fi5er Prefor(
) Fi5er t*pe
6 -o.in& for( that can 5e spra*e" into a ' prefor(6 -o.in& for( that is /o.en into a &lass sheet an" then for(e" to
shape 8prefor(:
Sheet Mol"in& Co(pon" 8SMC:
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!!
Sheet Mol"in& Co(pon" 8SMC:
) SMC is the paste that is co(pression (ol"e"
6 E pol*ester resin an" str*rene, /hich pol*(eri+es an" crosslin;s6 E &lass fi5ers 81 fi5ers:
6 E Calci( Car5onate
Processin& of Co(posites
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!#
Processin& of Co(posites) Open Mol" processes
6 ac( 5a&, pressre 5a&, SC-IMP
6 atocla.e$ ppl* ac( Pressre an" Heat in an o.en /hich can 5e # feet to 00 feet lon&
Strctral -IM
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!D
Strctral -IM
) Fi5er prefor( is place" into (ol"7
) Pol*ol an" Isoc*anate li4i"s are inBecte" into a close"(ol" an" reacte" to for( a rethane7
Processin& of Co(posites
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!@
Processin& of Co(posites
) Open Mol" processes
6 Han" la*'p an" Spra*'p
6 Fila(ent /in"in&
Co(posite Classifications
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!>
Co(posite Classifications) -esin 8or (atri=: t*pe
6 Ther(oset resins' those that n"er&o a che(ical cross'lin;in& reaction
) %po=*Pol*esterPol*rethane Phenolic
) Silicone Mela(ine6 Ther(oplastic resins' those that are for(e" n"er heat
) Pol*a(ines 8n*lon: 8short an" lon& fi5ers:
) Pol*esters 8short an" lon& fi5ers:
) Pol*prop*lene 8short, lon& fi5ers an" continos fi5ers:
) Other ther(oplastic resins 8short an" lon& fi5ers:
) Fi5er -einforce(ents6 Glass for reinforce" co(posites /ith concentrations less than #0E /ei&ht
6 Car5on fi5er for ".ance" 8aerospace: co(posites /ith concentrations &reater than D0E 5* /ei&ht7
6 e.lar fi5er for ".ance" 8aerospace: co(posites7
) Core or 3a(inate strctres6 foa( core (aterial can 5e a""e" 8san"/iche": 5et/een the la*ers of resin an" fi5er7
6 Co(posite la(inate has a core (aterial /ith resin an" fi5er co(5inations
Processin& an" Co(posites estions
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!9
Processin& an" Co(posites estions
17 co(posite (aterial is a co(5ination of a reinforcin& ele(ent an" KKKKKKKKKKK7
27 Ho/ are a".ance" co(posites are "istin&ishe" fro( reinforce" plasticsKKKKKKKKK7 The fi5ers in a".ance" co(posites are sall* (a"e fro( /hat KKKKKKKKKKKK
!7 Ahat t/o fnctions "oes the (atri= of a co(posite ser.e KKKKKKKKKKKKKKKK
#7 Un"er /hat con"itions shol" &raphite fi5ers .erss car5on fi5ers 5e se" KKKKKKK
Chap 1#$ Cera(ics
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#0
Chap 1#$ Cera(ics) Cera(ic pplications
) Cera(ic Strctres) Glass
) ".ance" Cera(ics
)Processin& of Cera(ics
) -e.ie/ estions
Intro ct on
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#1
o c o
) Cera(ics are
6 co(ple= co(pon"s an" soltions that contain 5oth (etallic an"
non(etallic ele(ents,
6 heate" at least to incan"escence "rin& processin& applications,
6 t*picall* har" an" 5rittle,
6 e=hi5it hi&h stren&th an" hi&h (eltin& points,
6 e=hi5it lo/ ther(al an" electrical con"cti.it*7
) pplications
6 Potter*, 5ric;, tile, &lass, o.en/are, (a&nets, refractories 8resist hi&h
te(peratre:, cttin& tools76 Frnace linin&s an" tiles for space shttle "e to hi&h resistance to
heat7
6 Spercon"cti.it* applications
era( cs
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#2
) Tra"itional cera(ics are (a"e fro( clay, silica, and feldspar
) Strctral cla*s for 5ric;s, se/er pipes, "rain tiles, an" floor tilesare (a"e fro( natral cla*s (a"e fro( three 5asic co(ponents
) Tra"itional cera(ic pro"cts are china, "ental porcelain, an"sanitar*'/are
) Technical cera(ics are (ainl* pre co(pon"s or nearl* preco(pon"s of pri(aril* o=i"es, car5i"es, or nitri"es76 Car5i"es$ /ith Silicon, tn&sten, titani(, or tantal( Car5i"es
) %=tre(e har"ness an" /ear resistance allo/s Use for cttin& tools an" a5rasi.es
6itri"es$ /ith
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#
) Cera(ics co(es fro( Gree; /or" keramos, /hich (eans
potters clay7
) Cera(ics are "i.erse &rop of non(etallic, inor&anic soli"
co(pon"s /ith a /i"e .ariet* of co(positions an"
properties7
) Cera(ics are cr*stalline co(pon"s (a"e p of (etallic an"non(etallic co(pon"s /ith properties that "iffer fro( the
constitents7
)Cera(ics in the for( of potter* are a(on& the ol"estpro"cts (anfactre" 5* h(ans7
6 Cla* is ine=pensi.e (aterial an" is fon" thro&hot the /orl"7
6 %arl* cla* pro"cts /ere sn "rie" not fire"7
6 Firin& as se" in potter* "ates 5ac; to aron" 2000 to 000
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#!
p) Cera(ics are cr*stalline li;e steel 5t ha.e fe/ free electrons
at roo( te(peratre an" ths are lo/ con"cti.it*7
) Cera(ics stren&ths ha.e hi&her co(pressi.e than tensile7
) Cera(ics are totall* elastic, e=hi5itin& no plasticit* /henloa" is applie" /ith little or no "efor(ation prior to fractre7
) In &eneral cera(ics ha.e the hi&hest (eltin& points of an*(aterials7 -an&e fro( #00F to as hi&h as @000F7
) Manfactrin& of cera(ics in.ol.es65len"in& fine startin& (aterials /ith /ater to for( (ass that is shape"
6 for(ation incl"es e=trsion, pressin&, an" castin&,
6 se of potter?s /heel for cps, 5o/ls, sacers, etc7
6 e=tr"e" to (a;e 5ar shapes or pore" into (ol" asslipslrr*
6 after for(in& pro"ct is "rie" to re(o.e /ater an" fire" for stren&th
6 for(in& pro.i"es fsion 8sintering: an" che(ical reaction for 5on"in&
6 &la+in& /ith cera(ic coatin& for s(ooth srface
era( cs Mater a s) Properties
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##
) Properties
6 ar* "epen"in& on co(position, (icrostrctre, an" processin&7
6 %=cellent resistance to
) co(pressi.e loa"s, a5rasion, heat, an" stainin&
) che(ical attac;s, /eather attac;s, 5en"in& 8e=cellent ri&i"it*:
6 Poor resistance to tensile loa"s, spallin& 8ther(al crac;in& cera(ics:
6 Most cera(ics /ill crac; if ther(al c*cle", e=cept P*re= &lass /hich contains 5oric
o=i"e to pro.i"e e=pansion properties7
) pplications6 "ielectric (aterials for capacitors /ith "is; capacitors 8(ainl* 5ari( titanate:
5ein& the (ost co((on7
6 Se(icon"ctor applications /ith sintere" o=i"es, e7&7, ther(istors, /hich are
ther(all* sensiti.e resistors se" for te(peratre control
6 Pie+oelectric cera(ics 8
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#D
) Glasses are "escri5e" as sper'coole" li4i"s76 Glasses "o not 5eha.e li;e (etals 5t (ore li;e pol*(ers /hen
coole" fro( (olten con"ition
) Metals e=hi5it a "efinite 4antit* of heat &i.en off /hen coole" an" for( acr*staline 8or re&lar: strctre /hen coole"7
6 Heat is calle" heat of soli"ification
) Pol*(ers e=hi5it chan&es in .ol(e /hen coole" /hich (a* for( a cr*stallineor a(orphos strctre "epen"in& pon the natre of the pol*(er an" .erss
te(peratre that has an inflection point, ;no/ as &lass transition te(peratre7) Glass is a transparent silica pro"ct /hich (a* for( an a(orphos or
cr*stalline strctre "epen"in& pon heat treat(ent "rin& pro"ction7
) Glass "o not e=hi5it an* in"ication of transition or a clear point of inflection/hen coolin& fro( (olten state7
) Glass is consi"ere" a .iscos li4i" /hen coole" fro( (olten state7
) Glass has the appearance an" feel of a soli" (aterial 5t /ill flo/ li;e a li4i"&i.en ti(e, e7&7, thic;er &lass at 5otto( of /in"o/ pane7
6 Cr*stallinit* of &lasses is (easre" /ith ra*s an" 'ra* "iffraction7) More cr*stalline the &lass the (ore ra*s are "iffracte"
ass Man actr n&
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&
) Glass 5lo/in& process
6 Glass 5lo/pipe is a hollo/ iron t5e fro( ! to # ft lon& /ith a ;no5 at
one en" an" a (othpiece at the other en"76 ip ;no5 en" into (elte" &lass, /here &lass stic;s to the en" of pipe7
6 ir is 5lo/n &entl* /hile rotatin& pipe /hich pro"ces a hollo/ 5l5
of &lass, /here the thic;ness of the 5l5 "epen"s on si+e of 5l57
6 The 5l5 cools an" soli"ifies into a n(5er of s*((etrical shapes7
6 Mol"s are se" to rapi"l* cool &lass an" allo/ (ore (an* shapes,
incl"in&, 5ottles, "ishes, la(ps, an" Bars7
) Co(position6 Glass is (a"e pri(aril* of san" 8silicon "io=i"e:
6 Silica or 4art+ &lass is pre silicon "io=i"e 8.er* sta5le:
6 Ain"o/ &lass is (a"e of san" 8SiO2:, li(estone 8CaCO:, an" so"a ash
8a2Co:
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